Child resistant peel pouch

ABSTRACT

Disclosed are packages for dispensing a product, the package including: a first layer; a second layer; a tab seal zone in which the first layer is joined to the second layer by a seal, the tab seal zone defining a first tab and a second tab; a first perforation in the first layer and a second perforation in the second layer, the first perforation defining a tear path in the first layer and the second perforation defining a tear path in the second layer, wherein at least one of the first and second perforations at least partially defines a boundary separating the first tab and the second tab; and a fold guide located in the tab seal zone, the fold guide indicating a fold line that intersects the first perforation and the second perforation across the boundary separating the first tab and the second tab.

CROSS-REFERENCE TO RELATED APPLICATIONS

Co-pending U.S. patent application Ser. No. 15/616,666, filed Jun. 7,2017 and entitled Easy-Open Peel Pouch, is incorporated herein byreference in its entirety. Published U.S. Patent Application2013-0308882, filed May 17, 2013 and also entitled Easy-Open Peel Pouch,is incorporated herein by reference in its entirety.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a semi-transparent view of a child resistant pouch accordingto some examples.

FIG. 2 is a top view of the child resistant pouch of FIG. 1.

FIG. 3 is a semi-transparent view of an alternative example of a childresistant pouch.

FIG. 4 is a top view of the child resistant pouch of FIG. 3.

FIG. 5 is a semi-transparent view of an alternative example of a foldguide for a child resistant pouch.

FIG. 6 is a semi-transparent view of an alternative example of a foldguide for a child resistant pouch.

FIG. 7 is a semi-transparent view of an alternative example of a childresistant pouch.

FIG. 8 is a semi-transparent view of an alternative example of a childresistant pouch.

FIG. 9 is a partial side view of a child resistant pouch according tosome examples.

FIG. 10 is a perspective view showing a method for opening a childresistant pouch according to some examples.

FIG. 11 is a top view of a web of child resistant pouches during anassembly process, according to some examples.

While embodiments herein are susceptible to various modifications andalternative forms, specifics thereof have been shown by way of exampleand drawings, and will be described in detail. It should be understood,however, that the scope herein is not limited to the particular examplesdescribed. On the contrary, the intention is to cover modifications,equivalents, and alternatives falling within the spirit and scopeherein.

DETAILED DESCRIPTION

Disclosed herein are examples of child resistant pouches. The pouchesare configured to be difficult for a child to open.

FIG. 1 shows a pouch 100 for containing and dispensing a product 112. Insome examples, the pouch 100 includes tactile features 134. The tactilefeatures 134 may be, for example, an aperture, one or more slits,grooves, bumps, recesses, embossing, or debossing on the surface of thepouch 100. The tactile features 134 provide grip for opening the pouch100. In alternative examples, the tactile features 134 may be omitted.

The pouch 100 is constructed from a first layer 102, a second layer 104(on the back side of the first layer 102 in FIG. 1). The first layer 102and the second layer 104 are joined together in a product seal zone 106where the first layer 102 is joined to the second layer 104 by a seal107. The product seal zone 106 can be configured such that the firstlayer 102 and the second layer 104 are joined until one layer is peeledaway from the other layer. The product seal zone 106 can be configuredsuch that when the first layer 102 is separated from the second layer104, the seal 107 is broken but each of the layers 102, 104 remainsrelatively intact.

The product seal zone 106 has an inner perimeter 108 and an outerperimeter 114 that define the bounds of the product seal zone 106. Theinner perimeter 108 of the product seal zone 106 defines an unsealedpouch area 110 for containing the product 112. The seal 107 shields theproduct 112 from exposure. The pouch 100 has a tab end 160 and a productend 165 that define first and second ends of the pouch 100. The pouch100 has a first side 115 and a second side 117 that define a first sideedge and a second side edge of the pouch 100.

In the example of FIG. 1, the first layer 102 and the second layer 104are sealed in the product seal zone 106 and in a tab seal zone 130. Insome examples, the first layer 102 and the second layer 104 are joinedby a peelable seal. In some examples, the first layer 102 and the secondlayer 104 are not sealed in an unsealed portion 116 situated between theproduct seal zone 106 and the tab seal zone 130. The first layer 102 andthe second layer 104 are also not sealed in the unsealed pouch area 110.

The pouch 100 has an outer perimeter 114 that defines the edges of thepouch 100. The outer perimeter 114 of the tab seal zone 130 at leastpartially defines a first tab 122 and a second tab 124.

The pouch 100 also includes at least one fold guide in the tab seal zone130. In some examples, the pouch 100 includes a first fold guide 181 inthe first tab 122 and a second fold guide 183 in the second tab 124. Thefirst and second fold guides 181, 182 indicate a fold line that extendsacross the pouch 100, which passes through both the first tab 122 andthe second tab 124. As will be discussed further in relation to FIG. 10,opening the pouch 100 requires folding the pouch 100 at the fold lineand severing the first tab 122 from the second tab 124, for example bytearing the first layer 102 and the second layer 104. The fold lineintersects a first perforation 132 in the first layer 102 and a secondperforation 133 in the second layer 104 across a boundary separating thefirst tab 122 and the second tab 124, which will be discussed below.

The fold guides 181, 182 can comprise at least one of a number ofdifferent indicators. For example, the fold guides 181, 182 can compriseat least one of a cut in the first or the second layer 102, 104 in whichthe cut does not intersect the perimeter 114 of the pouch 100; a crease;a perforation in at least one of the first layer 102 and the secondlayer 104; a debossed or embossed pattern in a surface of at least oneof the first layer 102 and the second layer 104; and a printed graphicor text on the surface of at least one of the first layer 102 and thesecond layer 104. It is anticipated that other indicators couldalternatively be used to indicate the fold line, and the examples listedhere of different types of fold guides is not exhaustive.

In the example of FIG. 1, the fold guides 181, 182 are shown asmicroperforations in at least one of the first layer 102 and the secondlayer 104. In some examples, both the first layer 102 and the secondlayer 104 contain these microperforations. In some examples, themicroperforations of the first fold guide 182 and the second fold guide182 in the first layer 102 and the second layer 104 overlap; inalternative examples, a fold guide in the first layer 102 can benon-overlapping with a fold guide in the second layer 104.

A first perforation 132 in the first layer 102 at least partiallydefines a boundary separating the first tab 122 and the second tab 124.The first perforation 132 defines a tear path 136 in the first layer102. The tear path 136 is the line along which a user will tear open thefirst layer 102 of the pouch 100 in order to break the seal 107 toexpose the product 112 inside of the pouch 100. In the example of FIG.1, the tear path 136 in the first layer 102 is nonlinear. The firstperforation 132 is, for example, a microperforation, which is made usinga die cut process by a die having very fine nicks in the blade that arevery close together.

The second layer 104 comprises a second perforation 133 that may be amicroperforation similar to the first perforation 132. In the drawing ofFIG. 1, the second perforation 133 in the second layer 104 is depictedas a dashed line in the area of the unsealed portion 116. The secondperforation 133 also extends into the tab seal zone 130. The secondperforation 133 in the second layer 104 at least partially defines theboundary separating the first tab 122 and the second tab 124. The secondperforation 133 defines a tear path 137 in the second layer 104. Thetear path 137 is the line along which a user will tear open the secondlayer 104 of the pouch 100 in order to break the seal 107 to expose theproduct 112 inside of the pouch 100. In the example of FIG. 1, thesecond tear path 137 is nonlinear. In the example of FIG. 1, thenonlinear portion of the tear path 136 in the first layer 102 does notoverlap the nonlinear portion of the tear path 137 in the second layer104.

In the example of FIG. 1, the first perforation 132 of the first layer102 overlaps the second perforation 133 of the second layer 104 in thetab seal zone 130, such that the first perforation 132 and the secondperforation 133 are aligned in the tab seal zone 130. In some examples,the first perforation 132 overlaps the second perforation 133 along aline segment.

In some examples, there is a non-perforated portion 121 of the tab sealzone 130 that separates the first perforation 132 from the perimeter114. In other words, the first perforation 132 does not extend to theperimeter 114 of the pouch 100.

In some examples, the first perforation 132 extends from the tab sealzone 130 through the unsealed portion 116 to a first edge 115 of theperimeter 114 of the pouch 100. In some examples, the second perforation133 extends from the tab seal zone 130 through the unsealed portion 116to a second edge 117 of the perimeter 114. In some examples, the firstperforation 132 and the second perforation 133 overlap in the tab sealzone 130, and do not overlap in the unsealed portion 116 of the pouch100. In some examples, the first perforation 132 extends from the tabseal zone 130 into the unsealed portion 116 without extending to theouter perimeter 114 of the pouch 100; in other words, non-perforatedportions of the first layer 102, adjacent to the first edge 115 and atab end 160 of the pouch 100, separates the first perforation 132 fromthe perimeter 114 of the pouch 100 at each end of the first perforation132. Similarly for the second perforation 133, in some examples,non-perforated portions of the second layer 104 separate the secondperforation 133 from the perimeter 114 of the pouch 100 at each end ofthe second perforation 133. In the example of FIG. 1, the firstperforation 132 does not extend to the second edge 117 of the perimeter114, and the second perforation 133 does not extend to the first edge115 of the perimeter 114. In alternative examples, the first perforation132 and the second perforation 133 could overlap entirely.

In some examples, there is a void 120 between the first tab 122 and thesecond tab 124. The shape of the void 120 is defined by the perimeter114. In alternative examples, the void 120 is omitted, in which case theouter perimeter 114 is a straight line across a tab end 160 of the tabseal zone 130.

In one embodiment of the manufacturing process, the first and secondperforations are formed during a single die-cutting step. In anotherembodiment of the manufacturing process, separate steps are used fordifferent portions of the perforations. The first and secondperforations overlap along the straight line segment that divides thetabs. The first and second perforations have non-overlapping segmentsthat include the non-linear portions. In one embodiment, thenon-overlapping segments are cut into the respective layers in onedie-cutting step, while the overlapping segments that divide the tabsare cut into the layers in a subsequent die-cutting step. In oneembodiment, the subsequent die-cutting step is the same step where theouter perimeter of the package is cut.

Turning to FIG. 10, the pouch 100 of FIGS. 1 and 2 is shown in theprocess of opening the pouch 100. A user opens the pouch 100 to exposethe product 112 by first folding over the pouch 100 at the fold line1001 indicated by the fold guides 181, 182. The fold line 1001 overlapsthe first perforation 132 and the second perforation 133 at anintersection point 190. In the example of FIG. 10, the fold line 1001 isapproximately perpendicular to the first perforation 132 and the secondperforation 133 at the intersection point 190 where the perforations132, 133 overlap.

Folding over the pouch 100 along the fold line 1001 defines a first flapportion 1022 in the first tab 122 and a second flap portion 1024 in thesecond tab 124 at the tab end 160 of the pouch 100. Folding the pouch100 along the fold line 1001 also defines a product portion 1050 of thepouch 100 on the opposite side of the fold line 1001. Initially, beforeopening the pouch 100, the first flap portion 1022 and the second flapportion 1024 are joined together, with the first tab 122 adjoining thesecond tab 124. Opening the pouch 100 requires a user to exert force onthe first tab 122 in a first direction, and to exert force in anopposite direction on the second tab 124. This shear force causes thefirst perforation 132 and the second perforation 133 to be severed atthe intersection point 190. (In FIG. 10, the perforation 133 in thesecond layer 104 is depicted as a dashed line; if the pouch 100 isopaque, this would not be visible when viewed from the direction of thefirst layer 102.) Then, the opposing forces on the first tab 122 and thesecond tab 124 cause the perforations 132, 133 to be severed along thetear path 136 of the first layer 104 and the tear path 137 of the secondlayer 104. In some examples, the perforations 132, 133 tear in twodirections: the perforations tear along a force vector directed from theintersection point 190 toward the tab end 160, and at the same time, theperforations 132, 133 tear along a force vector directed from theintersection point 190 toward the product end 165. As the first tab 122and the second tab 124 are pulled farther and farther apart, the firsttear path 136 of the first layer 102 veers in the direction of the firstedge 115, causing the first layer 102 to be severed along a firstsegment 1030 of the first perforation 132 that does not overlap thesecond perforation 133. Similarly, the second tear path 137 of thesecond layer 104 veers in the direction of the second edge 117, causingthe second layer 104 to be severed along a second segment 1033 of thesecond perforation 133 that does not overlap the first perforation 132.

Pulling the first tab 122 and the second tab 124 apart, combined withsevering the first perforation 132 and the second perforation 133,allows the seal 107 of the product seal zone 106 to be peeled apart,exposing the products 112 inside of the pouch 100. At first, the seal107 resists separation. When the user applies a sufficient force againstthe resistance of the seal 107, the force causes the seal 107 to bebroken first at an apex 150 of the product seal zone 106. The firstlayer 102 then begins peeling apart from the second layer 104. As thefirst tab 122 and the second tab 124 are pulled farther and fartherapart, more of the seal 107 is broken. Eventually, the seal 107 of theproduct seal zone 106 will be broken as the first layer 102 and thesecond layer 104 are peeled apart. This allows the product 112 to beremoved from the pouch 100.

Returning to FIG. 1, in some examples, the tear path 136 in the firstlayer 102 starts at a longitudinal centerline of the package and extendsto a first edge 115 of the pouch 100, and the tear path 137 in thesecond layer 104 starts at the longitudinal centerline of the pouch 100and extends to the second edge 117 of the pouch 100. In some examples,the tear path 136 overlaps the tear path 137 at the centerline in thetab seal zone 130.

The first layer 102 and the second layer 104 can include a variety ofmaterials and combinations of materials that are generally known in theart, such as a polyester film, spunbonded olefin, DuPont TYVEK® brandspunbonded olefin, linear low density polyethylene with polybutylene,biaxially oriented polyester film, polypropylene film, high densitypolyethylene film, acrylonitrile co-polymer film, BAREX® brandacrylonitrile co-polymer film available from BP Chemicals, Inc., castpolyethylene terephthalate (PET) or polyethylene terephthalate glycol(PETG) film, metal foil, aluminum foil, poly-vinylidene dichloride(PVDC) film, co-extruded films containing ethylene vinyl alcohol polymer(EVOH), polyvinyl alcohol (PVA) film, polyamide film, vinyl film, highdensity polyethylene (HDPE), ACLAR® brand film, cold or thermo formingfilms, multilayer heat sealable pouch films, or composite laminations orcoatings that contain the same. In a variety of examples, the firstlayer 102 and the second layer 104 are heat sealable or sealable usingultrasonic welding, pressure or vibration. In some examples, only one ofthe first layer 102 and second layer 104 is heat sealable, and the otheris a compatible material to create a peelable seal. In one example, eachof the first and second layers 102, 104 includes a polyester layer, suchas a DuPont TYVEK® brand spunbonded olefin, a tie layer and a sealantlayer. In one example, the polyester film, tie layer and sealant layerare coextruded or laminated to form a single film. One example of anappropriate sealant layer is linear low density polyethylene withpolybutylene, which is activated by heat to bond to the other layer. Insome examples, the layers 102, 104 are joined by methods other than heatsealing. For example, the layers 102, 104 may be joined by ultrasonicwelding in some examples. In some examples, the layers 102, 104 may bejoined by more than one method, such as both heat sealing and ultrasonicwelding.

In a variety of examples, the first layer 102 and the second layer 104are substantially non-permeable. In a variety of examples, the firstlayer 102 and the second layer 104 are substantially permeable. Forexample, a layer that includes a metal foil layer will be substantiallynon-permeable, while a layer that includes a DuPont TYVEK® brandspunbonded olefin will be permeable. In a variety of examples, the firstlayer 102 and the second layer 104 are substantially flexible, althoughin some examples one of the first layer 102 or the second layer 104 orboth are substantially rigid. In some examples, one or both of thelayers is transparent so that the product 112 is visible through thetransparent layer. Alternative terms that can be used to describe thefirst layer 102 and the second layer 104 include film, sheet, web, andthe like.

The first layer 102 is generally coextensive with the second layer 104and, as mentioned above, the first layer 102 and second layer 104 are atleast partially joined with a peelable seal. Generally, the peelableseal is a hermetic bond between the contacting surfaces of the firstlayer 102 and second layer 104. The peelable seal can be formed by anyappropriate method known in the art. In a variety of examples, peelableseal is a heat seal or melt bonded relationship caused by theapplication of heat and pressure. In an alternative example, peelableseal is formed with a suitable adhesive applied to at least one of thecontacting surfaces of the first layer 102 and second layer 104. In atleast one example, the peelable seal is re-sealable, thereby allowing auser to reclose the pouch 100.

In general the peelable seal is configured to have strength conducive toallowing a user to peel the first layer 102 and the second layer 104apart without the use of tools, to access the product 112 there between.In one example, the peelable seal strength is in the range of 1.25 to 2pounds per linear inch of seal when pulled apart at 180 degrees at 12inches per minute travel rate according to testing procedure TAPPI T-494as published by the Technical Association of the Pulp and PaperIndustry. In some examples the peelable seal strength is in the range of1.0 to 2.5 pounds per linear inch of seal. In a variety of examples thepeelable seal has strength in the range of 0.25 to 3.5 pounds per linearinch of seal.

FIG. 2 is a top view of the child resistant pouch of FIG. 1. FIG. 2shows only the first layer 102 of the pouch 100. The pouch 100 has alongitudinal centerline. The tear path 136 of the first layer 102 startsalong the longitudinal centerline toward the end 160 of the pouch 100.In the example of FIGS. 1 and 2, the tear path 136 for the first layer102 would begin at the intersection point 190 and extend in twodirections: first, along the longitudinal centerline toward the tab end160, and also in the opposite direction along the longitudinalcenterline toward the product end 165. A non-linear portion of the tearpath 136 then directs the first layer 102 two sever along a diagonalpath extending from the centerline to the first edge 115 of the pouch100. FIG. 2 shows an alternative example of a fold guide, in which thefold guides comprise a continuous cut in at least one of the first layer102 and the second layer 104, instead of the microperforated fold guidesof FIG. 1.

As shown in FIG. 2, the non-linear portion of the perforation 132 has aradius of curvature. The non-linear portion of the perforation 133 alsohave a radius of curvature. This radius of curvature reduces thelikelihood of the layer that defines the perforation from ripping alonga line other than along the tear path 136. A small radius of curvatureis more likely to rip the layer in an unwanted location than a largeradius of curvature. Although the example of FIG. 2 shows one particularradius of curvature, it is anticipated that other examples couldincorporate a larger or smaller radius of curvature, depending upon theparticular application of the technology.

FIG. 3 is a semi-transparent view of an alternative example of a childresistant pouch. In this example, the pouch has a first layer and asecond layer, where the first layer and the second layer are joined inat least a product seal zone and a tab seal zone, as in the example ofFIG. 1. FIG. 3 shows fold guides cut in the first tab and the secondtab.

The alternative example of FIG. 3 has a first perforation and a secondperforation; however, the first perforation in the first layer 102comprises a first segment and a second segment. In the example of FIG.3, the first segment of the first perforation intersects the secondsegment of the first perforation in the first layer 102, as opposed tothe example of FIG. 1, in which the first perforation 132 comprises acontinuous segment. The first and second segments each have twoendpoints, unlike the example of FIG. 1 where the first perforation is acontinuous segment. In the example of FIG. 3, the first segment of thesecond perforation in the second layer 104 overlaps the first segment ofthe first perforation in the first layer 102.

In FIG. 3, the second perforation also includes a first segment and asecond segment. The first segment of the second perforation intersectsthe second segment of the second perforation at an intersection point inthe second layer 104. The second segment of the first perforation andthe second segment of the second perforation each have a non-linear endthat intersects their first respective segments. The non-linear portionsof these segments are provided in order to reduce the likelihood thatthe layers tear through the centerline of the package. It has been foundthat when these non-linear portions are omitted, the perforations havean increased likelihood of not tearing properly, if other factors remainthe same.

The second segment of the first perforation A and the second segment ofthe second perforation B are not intended to meet the end of the firstsegments C of the first and second perforations. In one manufacturingembodiment, the second segments A and B are formed during the diecutting process in one step, while the first segments C are formedduring a later. In one embodiment, the first segments C are cut at thesame time as the outer perimeter of the pouch. Because the secondsegments A and B are not intended to form a continuous segment with thefirst segments C, the manufacturing process can have more permissivetolerances for a re-registration process between the die-cutting stepswhen making the package of FIGS. 3 and $, compared to the package ofFIGS. 1 and 2.

FIG. 4 is a top view of the child resistant pouch of FIG. 3, with onlythe first layer showing. FIG. 4 demonstrates force vectors V1 and V2that represent the directions along which the first layer is torn whenthe package is opened. In particular, the first layer is severedbeginning at the intersection point, and then is severed along thedirection of V1 and along the direction of V2. The tear path of thefirst layer then veers toward the side edge of the package along thesecond perforation segment of the first perforation.

FIG. 5 is a semi-transparent view of an alternative example of a foldguide for a child resistant pouch. In this example, the fold guide is apattern of dimples that may be created by embossing or debossing. Thedimples may be the same as the tactile features present in the first taband the second tab. The pattern of dimples extends along the fold line,indicating the line along which the user should fold the first andsecond tabs. FIG. 5 also shows that the fold line intersects theperforation, and that the perforation defines the boundary between thefirst and second tabs. Furthermore, in the example of FIG. 5, theperforation extends to the perimeter of the package.

Turning to FIG. 6, the example of FIG. 6 shows a fold guide with aprinted graphic and printed text on the surface of the package. In thisalternative example, the first and second perforations do not extend tothe perimeter of the pouch. Instead, a non-perforated portion of thepouch separates the perforation from the perimeter of the pouch.

Turning to FIG. 7, an alternative example of a child resistant pouchincludes both perforations and continuous cuts. A perforation in thefirst layer extends along the lateral centerline of the pouch. Theperforation defines a tear path in the first layer. A full guide,comprising perforations, intersects the perforation at an intersectionpoint. The fold guide indicates a fold line along which a user shouldfold the package. Instead of micro perforations extending across thewidth of the pouch, FIG. 7 uses a continuous cut in the first layer anda continuous cut in the second layer. A radial cut in at least one ofthe first layer and the second layer prevents the layer from tearingdown the center of the pouch when the first layer and second layer arebeing pulled apart.

Turning to FIG. 8, an alternative example of a child resistant pouchincludes a perforation and full guide similar to that of FIG. 7.However, no tactile features are present along the fold line. Aperforation in the first layer and a perforation in the second layeroverlap in the tab seal zone, and do not overlap in an unsealed portionof the pouch. A radial cut at the base of the first and the second tabsprevents the first layer from tearing anywhere other than along the tearpath defined by the perforation in the first layer.

FIG. 9 is a partial side view of a child resistant pouch according tosome examples such as FIG. 2. FIG. 9 is a schematic view to aid inexplaining some aspects of the various examples; for example, the twoseals defining the product seal zone and the tab seal zone are depictedas being separate structures. But in reality, this represents a bondbetween the first and second layers that is not a separate structure.

This side view of FIG. 9 shows the product seal zone, the tab seal zone,and an unsealed portion of the package disposed between the product sealzone and the tab seal zone. In this example, the fold guide is a cut inthe first layer and a cut in the second layer. The package is shownbeing folded over. The fold defines a flap portion of the pouch on oneside of the fold, and a product portion on the opposite side of thefold. The perforation in the first layer ends at the side edge of thepouch at the unsealed portion of the pouch.

FIG. 11 shows a combined web which includes a first layer web and asecond layer web. The combined web includes a plurality of individualpouches, having one example configuration, each having an unsealed poucharea and a product in the unsealed pouch area. The individual pouchesare separated from each other by a web matrix.

The first layer web and the second layer web are sealed to form acombined web by sealing the first layer web to the second layer web atleast at one of a plurality of product seal zones and a plurality of tabseal zones, such that the first layer is joined to the second layer by apeelable seal.

The webs are generally sized to create multiple pouches; the webs may bevery long, also referred to as continuous, in the machine direction andhave a cross-machine direction of one to five packages, or more. In theexample of FIG. 11, the combined web holds four pouches in thecross-machine direction, and is very long in the machine direction. Thephrase “very long in the machine direction” is used to mean a web thatis typically substantially longer than it is wide, such as one-hundredor one-thousand times longer than its width, and is often processed onrolls.

In at least one example implementation, sealing the webs is accomplishedalong a line in a continuous motion. A seal plate can be used forjoining a first layer web and a second layer web with a heat seal orother seal at a seal zone to form the combined web. In such animplementation, the seal plate itself defines a product seal zone havingan inner perimeter and an outer perimeter, as well. Such a seal platealso defines a tab seal zone within individual pouches.

During the manufacturing process, at least one of the first layer weband the second layer web is provided with a perforation. The perforationdefines first and second tabs of the individual pouches. The individualpouches are furthermore provided with at least one fold guide. The foldguides are indicative of a fold line along which the finished pouchshould be folded. A number of techniques are suitable for the foldguides. For example, the fold guides can comprise at least one of a cutin the first or the second layer in which the cut does not intersect theperimeter of the pouch; a crease; a perforation in at least one of thefirst layer and the second layer; a debossed or embossed pattern in asurface of at least one of the first layer and the second layer; and aprinted graphic or text on the surface of at least one of the firstlayer and the second layer.

The combined web is then cut to produce at least one individual pouch.The pouch is cut along center machine-direction cut lines, cross-machinedirection cut lines and outer machine direction cut lines to separatethe individual pouch from a matrix. A web matrix allows for sometolerance in the sealing and cutting steps.

In some examples, each individual pouch is cut on two or more passes. Insome examples, perforation lines are made in a first die cuttingprocess, and in a second die cutting process, the individual pouches arecut along their perimeter from the web matrix to form the individualpouches. In some cases, cuts or perforations created in the first dieprocess must be aligned precisely with the cuts in the second dieprocess. In these cases, if the first die cut pass is not aligned withthe second die cut pass, the pouches will not open correctly. A processof re-registration is used to ensure that the second die cut willprecisely align with the first die cut.

In a variety of examples, each individual package is die cut around itsrespective outer perimeter. In at least one example implementation, thedie cutting is accomplished in a rotary die cutting station. In such anexample, the rotary die can cut against an anvil roll, for example. Inother examples, the packages are knife cut or guillotine cut at theirouter perimeters.

If the pouch includes embossing or debossing, such as to form the foldguide or tactile features on the tabs, the embossing step can happenduring the manufacturing process. Embossing is a technique in which amale die and a female die are used on two sides of a web to create araised pattern on the web. The inverse technique, called debossing, usesa male die and a female die on two sides of a web to create anindentation on the web. The steps of embossing or debossing can happensimultaneously with providing perforations, or separately.

It should be noted that, as used in this specification and the appendedclaims, the singular forms include the plural unless the context clearlydictates otherwise. It should also be noted that the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

All publications and patent applications referenced in thisspecification are herein incorporated by reference in their entirety.

The invention has been described with reference to various specific andpreferred embodiments and techniques. However, it should be understoodthat many variations and modifications may be made while remainingwithin the spirit and scope of the invention.

Definitions

Perforation: an intentionally damaged portion of the layer that weakensthe layer at a point or along a line segment. Although thisspecification uses the word “perforation,” it is not intended to limitthe scope of the present technology. Perforations can includemicroperforations, holes, a series of cuts or punctures, a scored areathat does not cut entirely through a layer, etc. A perforation does notsever the layer into two pieces at the perforation location. In contrastto a perforation, a continuous cut severs a layer into two distinctpieces.

Fold guide: a physical or printed mark indicating a location along whichthe user should fold the packaging. The fold guide could use a number ofdifferent indicators, e.g., a perforation, a continuous cut though aportion of the package, debossing, embossing, or a graphic or textindicating where to fold. Other types of fold guides are suitable andare within the scope of the present technology.

Overlap: refers to spatial relationships between elements on the firstlayer and elements on the second layer. For example, a perforation onthe first layer overlaps a perforation on the second layer when the twoperforations are aligned one on top of the other. Perforations on twodifferent layers can overlap at a single point or along a line segment.For example, a perforation on a first layer and a perforation on asecond layer can be oriented in different directions such that theyoverlap at a single point like an ‘X.’

Intersection: refers to spatial relationships between elements on asingle layer. When a first perforation segment on a first layer crossesa second perforation segment on the first layer, the two segments aresaid to intersect at an intersection point.

Sever: to break a connection between a first area and a second areawithin a single layer of packaging. Severing can refer to tearing alayer of the package along a tear path, e.g., along a perforation. Whena first perforation on a first layer overlaps a second perforation on asecond layer, severing the first layer and the second layer occurssimultaneously.

Other Embodiments

Various modifications and variations of the described invention will beapparent to those skilled in the art without departing from the scopeand spirit of the invention. Although the invention has been describedin connection with specific embodiments, it should be understood thatthe invention as claimed should not be unduly limited to such specificembodiments. Indeed, various modifications of the described modes forcarrying out the invention that are obvious to those skilled in the artare intended to be within the scope of the invention.

The invention is also described by the following enumerated items.

1. A package for dispensing a product, the package comprising:

A first layer;

A second layer;

A tab seal zone in which the first layer is joined to the second layerby a seal, the tab seal zone defining a first tab and a second tab;

A first perforation in the first layer and a second perforation in thesecond layer, the first and second perforations at least partiallydefining a boundary separating the first tab and the second tab, thefirst perforation defining a tear path in the first layer and the secondperforation defining a tear path in the second layer; and

A fold guide located in the tab seal zone, the fold guide indicating afold line that intersects the first perforation and the secondperforation across the boundary separating the first tab and the secondtab.

2. The package of any of items 1 and 3-22, wherein the first perforationoverlaps the second perforation along a line segment.

3. The package of any of items 1-2 and 4-22, wherein the firstperforation and the second perforation overlap entirely.

4. The package of any of items 1-3 and 5-22, further comprising anarc-shaped cut in at least one of the first layer and the second layerat a base of the first and second tabs.

5. The package of any of items 1-4 and 6-22, wherein at least a portionof the tear path in the first layer overlaps a portion of the tear pathin the second layer, and wherein at least a portion of the tear path inthe first layer does not overlap a portion of the tear path in thesecond layer.

6. The package of any of items 1-5 and 7-22, wherein a perimeter of thepackage defines a tab end adjacent to the tab seal zone and a productend opposite the tab end, wherein the first perforation and the secondperforation do not extend to the perimeter at the tab end.

7. The package of any of items 1-6 and 8-22, wherein the perimeterfurther defines a first side edge and a second side edge opposite thefirst side edge, wherein the first perforation extends to the first sideedge and does not extend to the second side edge, and wherein the secondperforation extends to the second side edge and does not extend to thefirst side edge.

8. The package of any of items 1-7 and 9-22, wherein the firstperforation and the second perforation do not extend to a perimeter ofthe package.

9. The package of any of items 1-8 and 10-22, wherein the tab seal zonecomprises a non-perforated area between a perimeter of the package andthe first and second perforations.

10. The package of any of items 1-9 and 11-22, wherein the tear path inthe first layer starts at a longitudinal centerline of the package andextends to a first side edge of the package, and the tear path in thesecond layer starts at the longitudinal centerline of the package andextends to a second side edge of the package.

11. The package of any of items 1-10 and 12-22, wherein the tear path inthe first layer at the centerline of the package overlaps the tear pathin the second layer at the centerline of the package.

12. The package of any of items 1-11 and 13-22, wherein the first tabadjoins the second tab.

13. The package of any of items 1-12 and 14-22, wherein at least aportion of the tear path in the first layer is non-linear and at least aportion of the tear path in the second layer is non-linear.

14. The package of any of items 1-13 and 15-22, wherein the non-linearportion of the tear path in the first layer does not overlap thenon-linear portion of the tear path in the second layer.

15. The package of any of items 1-14 and 16-22, wherein at least one ofthe first perforation and the second perforation is a single perforationsegment.

16. The package of any of items 1-15 and 17-22, wherein at least one ofthe first perforation and the second perforation comprises two or moreperforation segments.

17. The package of any of items 1-16 and 18-22, wherein at least one ofthe first perforation and the second perforation comprises:

a first perforation segment; and

a second perforation segment intersecting the first perforation segment.

18. The package of any of items 1-17 and 19-22, wherein the fold guideis located in a portion of the tab seal zone adjacent to an overlap ofthe first perforation and the second perforation.

19. The package of any of items 1-18 and 20-22, wherein the fold guideindicates a fold line that is perpendicular to the first perforation andthe second perforation at a point of overlap.

20. The package of any of items 1-19 and 21-22, wherein the fold guideis at least one of:

a cut in at least one of the first and second layers, wherein the cutdoes not intersect a perimeter of the package;

a crease;

a perforation in at least one of the first layer and the second layer;

an embossed pattern in a surface of at least one of the first layer andthe second layer;

a debossed pattern in a surface of at least one of the first layer andthe second layer;

printed text; and

a printed graphic on the surface of at least one of the first layer andthe second layer.

21. The package of any of items 1-20 and 22, wherein the fold guidedefines a flap portion in the tab seal zone at a tab end of the package,and a product portion in a product seal zone at a product end of thepackage.

22. The package of any of items 1-21, further comprising: a product sealzone opposite the tab seal zone, and an unsealed portion of the packagesituated between the product seal zone and the tab seal zone.

23. A method of opening a child-proof package, the method comprising:

folding a portion of the package along a fold guide to define a flapportion separated from a product portion of the package by a fold, thefold intersecting a first perforation in a first layer of the packageand a second perforation in a second layer of the package at anintersection point, wherein the first perforation overlaps the secondperforation; and

tearing the product portion and the flap portion along a first tear linedefined by the first perforation and a second tear line defined by thesecond perforation, the step of tearing including

severing the first layer and the second layer at the intersection pointon the fold,

after severing the first layer and the second layer at the intersectionpoint, tearing the package along a first tear vector and a second tearvector, the second tear vector oriented in a direction opposite thefirst tear vector,

severing the first layer along a first segment of the first perforationthat does not overlap the second perforation, and

severing the second layer along a first segment of the secondperforation that does not overlap the first perforation;

whereby the step of severing the first layer and the second layer causesa product inside of the package to be exposed.

24. A method of forming a package for containing and dispensing aproduct, the method comprising:

providing a first layer web and a second layer web;

placing a product on at least one pouch area of one of the first andsecond layer webs;

forming a combined web by sealing the first layer web to the secondlayer web at least at a product seal zone and a tab seal zone such thatthe first layer is joined to the second layer by a seal surrounding theat least one pouch area and a seal in the tab seal zone;

forming a perforation in the tab seal zone of at least one of the firstlayer web and the second layer web, the perforation defining a first taband a second tab of the package;

forming a fold guide in the tab seal zone of at least one of the firstlayer web and the second layer web, the fold guide being adjacent to theperforation; and

cutting at least one individual package around an outer packageperimeter to separate the individual package from the combined web.

25. The method of item 24, wherein the step of forming a combined webfurther comprises leaving an unsealed zone adjacent to an outerperimeter of the product seal zone where the first layer web is notsealed to the second layer web.

What is claimed is:
 1. A package for dispensing a product, the packagecomprising: A first layer; A second layer; A tab seal zone in which thefirst layer is joined to the second layer by a seal, the tab seal zonedefining a first tab and a second tab; A first perforation in the firstlayer and a second perforation in the second layer, the firstperforation defining a tear path in the first layer and the secondperforation defining a tear path in the second layer, wherein at leastone of the first and second perforations at least partially defines aboundary separating the first tab and the second tab; and A fold guidelocated in the tab seal zone, the fold guide indicating a fold line thatintersects the first perforation and the second perforation across theboundary separating the first tab and the second tab.
 2. The package ofclaim 1, wherein the first perforation overlaps the second perforationalong a line segment.
 3. The package of claim 1, wherein the firstperforation and the second perforation overlap entirely.
 4. The packageof claim 3, further comprising an arc-shaped cut in at least one of thefirst layer and the second layer at a base of the first and second tabs.5. The package of claim 1, wherein at least a portion of the tear pathin the first layer overlaps a portion of the tear path in the secondlayer, and wherein at least a portion of the tear path in the firstlayer does not overlap a portion of the tear path in the second layer.6. The package of claim 1, wherein a perimeter of the package defines atab end adjacent to the tab seal zone and a product end opposite the tabend, wherein the first perforation and the second perforation do notextend to the perimeter at the tab end.
 7. The package of claim 6,wherein the perimeter further defines a first side edge and a secondside edge opposite the first side edge, wherein the first perforationextends to the first side edge and does not extend to the second sideedge, and wherein the second perforation extends to the second side edgeand does not extend to the first side edge.
 8. The package of claim 1,wherein the first perforation and the second perforation do not extendto a perimeter of the package.
 9. The package of claim 1, wherein thetab seal zone comprises a non-perforated area between a perimeter of thepackage and the first and second perforations.
 10. The package of claim1, wherein the tear path in the first layer starts at a longitudinalcenterline of the package and extends to a first side edge of thepackage, and the tear path in the second layer starts at thelongitudinal centerline of the package and extends to a second side edgeof the package.
 11. The package of claim 10, wherein the tear path inthe first layer at the centerline of the package overlaps the tear pathin the second layer at the centerline of the package.
 12. The package ofclaim 1, wherein the first tab adjoins the second tab.
 13. The packageof claim 1, wherein at least a portion of the tear path in the firstlayer is non-linear and at least a portion of the tear path in thesecond layer is non-linear.
 14. The package of claim 13, wherein thenon-linear portion of the tear path in the first layer does not overlapthe non-linear portion of the tear path in the second layer.
 15. Thepackage of claim 1, wherein at least one of the first perforation andthe second perforation is a single perforation segment.
 16. The packageof claim 1, wherein at least one of the first perforation and the secondperforation comprises two or more perforation segments.
 17. The packageof claim 1, wherein at least one of the first perforation and the secondperforation comprises: a first perforation segment; and a secondperforation segment intersecting the first perforation segment.
 18. Thepackage of claim 1, wherein the fold guide is located in a portion ofthe tab seal zone adjacent to an overlap of the first perforation andthe second perforation.
 19. The package of claim 18, wherein the foldguide indicates a fold line that is perpendicular to the firstperforation and the second perforation at a point of overlap.
 20. Thepackage of claim 1, wherein the fold guide is at least one of: a cut inat least one of the first and second layers, wherein the cut does notintersect a perimeter of the package; a crease; a perforation in atleast one of the first layer and the second layer; a debossed pattern ina surface of at least one of the first layer and the second layer; anembossed pattern in a surface of at least one of the first layer and thesecond layer; printed text; and a printed graphic on the surface of atleast one of the first layer and the second layer.
 21. The package ofclaim 1, wherein the fold guide defines a flap portion in the tab sealzone at a tab end of the package, and a product portion in a productseal zone at a product end of the package.
 22. The package of claim 1,further comprising: a product seal zone opposite the tab seal zone, andan unsealed portion of the package situated between the product sealzone and the tab seal zone.
 23. A method of opening a child-proofpackage, the method comprising: folding a portion of the package along afold guide to define a flap portion separated from a product portion ofthe package by a fold, the fold intersecting a first perforation in afirst layer of the package and a second perforation in a second layer ofthe package at an intersection point, wherein the first perforationoverlaps the second perforation; and tearing the product portion and theflap portion along a first tear line defined by the first perforationand a second tear line defined by the second perforation, the step oftearing including severing the first layer and the second layer at theintersection point on the fold, after severing the first layer and thesecond layer at the intersection point, tearing the package along afirst tear vector and a second tear vector, the second tear vectororiented in a direction opposite the first tear vector, severing thefirst layer along a first segment of the first perforation that does notoverlap the second perforation, and severing the second layer along afirst segment of the second perforation that does not overlap the firstperforation; whereby the step of severing the first layer and the secondlayer causes a product inside of the package to be exposed.
 24. A methodof forming a package for containing and dispensing a product, the methodcomprising: providing a first layer web and a second layer web; placinga product on at least one pouch area of one of the first and secondlayer webs; forming a combined web by sealing the first layer web to thesecond layer web at least at a product seal zone and a tab seal zonesuch that the first layer is joined to the second layer by a sealsurrounding the at least one pouch area and a seal in the tab seal zone;forming a perforation in the tab seal zone of at least one of the firstlayer web and the second layer web, the perforation defining a first taband a second tab of the package; forming a fold guide in the tab sealzone of at least one of the first layer web and the second layer web,the fold guide being adjacent to the perforation; and cutting at leastone individual package around an outer package perimeter to separate theindividual package from the combined web.
 25. The method of claim 24,wherein the step of forming a combined web further comprises leaving anunsealed zone adjacent to an outer perimeter of the product seal zonewhere the first layer web is not sealed to the second layer web.